Encapsulation of electronic components with poly(arylene sulfide) containing mercaptosilane

ABSTRACT

Electronic components can be encapsulated with a poly(arylene sulfide) composition containing a mercaptosilane such as, for example, 3-mercaptopropyltrimethoxysilane.

This invention relates to poly(arylene sulfide) compositions. In another aspect this invention relates to the encapsulation of electronic components.

BACKGROUND

U.S. Pat. No. 4,337,182, incorporated by reference herein, describes a poly(arylene sulfide) composition suitable for encapsulating semi-conductors. The composition disclosed in that patent includes a small amount (about 0.5 to 3 weight percent) of an organic silane. The purpose of the organic silane, as taught by the patent, is to function as a coupling agent, to impart improved water resistance and to decrease the linear coefficient of expansion of the composition. The only organic silane species specifically identified are:

gamma-glycidoxypropyltrimethoxysilane

methyltrimethoxysilane

polyisoxymethoxysilane

vinyltris(2-methoxyethoxy)silane

beta-(3,4-epoxycyclohexyl)-ethyltrimethoxysilane

N-beta(N-vinylbenzylamine)ethyl gamma-aminopropyltrimethoxysilane monohydrogen chloride

The patent further teaches that the last of these silanes is preferred. Another name for this preferred silane is N-{2-[3-(trimethoxysilyl)propylamino]ethyl}-p-vinylbenzylammonium chloride.

The Phillips Chemical Company (a division of Phillips Petroleum Company, Bartlesville, Okla.) has marketed an encapsulating composition containing this silane. The composition comprises:

(a) poly(phenylene sulfide),

(b) fiber glass,

(c) talc or silica, and

(d) N-{2-[3-(trimethoxysilyl)propylamino]ethyl}-p-vinylbenzylammonium chloride.

Electronic components are coated or encapsulated with this poly(phenylene sulfide) composition to maintain electrical insulation, to provide mechanical protection and to otherwise shield the component from exposure to its environment.

One very important property of any encapsulation material is electrical resistance. In use, the encapsulation material is generally subjected to a hostile environment that adversely affects the desired properties of the material. Of particular concern are the effects of high temperature conditions and/or of high humidity conditions. Such conditions can cause a decrease in the electrical resistance of the encapsulation material.

It is an objective of those of skill in the art of poly(arylene sulfide) encapsulation compositions to produce compositions which retain high electrical resistance when subjected to hostile conditions such as, for example, high temperature and high humidity. It is also an objective of those of skill in this art to produce poly(arylene sulfide) compositions of increased electrical resistance.

Another objective of those of skill in the art is to produce poly(arylene sulfide) compositions of decreased specific conductivity.

SUMMARY OF THE INVENTION

The electrical resistance of a poly(arylene sulfide) composition is increased by the presence of a mercaptosilane such as, for example, 3-mercaptopropyltrimethoxysilane. Also, the specific conductivity of the composition is decreased by the presence of the mercaptosilane.

Broadly, our invention encompasses the encapsulation of electronic components with a poly(arylene sulfide) composition, such as, for example, a poly(phenylene sulfide) composition, containing at least one mercaptosilane such as, for example, 3-mercaptopropyltrimethoxysilane. The mercaptosilane is defined to be, for the purposes of this invention, an organosilane having an --SH functional group.

Our invention includes, but is not limited to, poly(arylene sulfide) compositions containing, in addition to mercaptosilane, other components such as glass and talc or silica.

OBJECTS OF THE INVENTION

It is an object of our invention to increase the electrical resistance of a poly(arylene sulfide) composition.

It is a further object of this invention to decrease the specific conductivity of a poly(arylene sulfide) composition.

It is also an object of our invention to coat or encapsulate electronic components with an improved composition.

These objects and other objects and advantages will be apparent to a person of ordinary skill in the art from this disclosure and the appended claims.

DESCRIPTION OF THE DRAWING

FIG. 1 corresponds to Example VI and graphically illustrates the advantage of 3-mercaptopropyltrimethoxysilane in a poly(phenylene sulfide) composition.

DESCRIPTION OF THE INVENTION

1. Broad Description

Uncured or partially cured poly(arylene sulfide) whether homopolymer, copolymer, terpolymer, and the like, or a blend of such polymers, can be used in the practice of our invention. The uncured or partially cured polymer is a polymer the molecular weight of which can be increased by either lengthening of a molecular chain or by crosslinking or by combination of both by supplying thereto sufficient energy, such as heat. Suitable poly(arylene sulfide) polymers include, but are not limited to, those described in U.S. Pat. No. 3,354,129, incorporated by reference herein.

Examples of poly(arylene sulfide) compositions suitable for purposes of our invention include poly(2,4-tolylene sulfide), poly(4,4'-biphenylene sulfide) and poly(phenylene sulfide). Because of its availability and desirable properties (such as high chemical resistance, nonflammability, and high strength and hardness) poly(phenylene sulfide) is the presently preferred poly(arylene sulfide). Accordingly, poly(phenylene sulfide) compositions are the preferred encapsulation compositions of my invention.

In accordance with the broad concept of our invention electronic components are encapsulated with a poly(arylene sulfide) composition (such as, for example, a poly(phenylene sulfide) composition) containing at least one mercaptosilane (such as, for example, 3-mercaptopropyltrimethoxysilane). The poly(arylene sulfide) composition can be, but is not required to be, a mixture of more than one poly(arylene sulfide). The poly(arylene sulfide) composition can contain, in addition to mercaptosilane, other components although the broad concept of our invention is not limited thereto.

Our invention also includes more detailed poly(arylene sulfide) compositions which are especially well suited for successful use as encapsulation compositions. These compositions are described later in this disclosure.

The preferred mercaptosilane is 3-mercaptopropyltrimethoxysilane or HSCH₂ CH₂ CH₂ Si(OCH₃)₃. This silane is preferred because of its extraordinary utility as an encapsulation composition additive. 3-Mercaptopropyltrimethoxysilane is especially effective in both increasing the electrical resistance of the compositions of our invention and decreasing the specific conductivity of these compositions.

The electronic components to be encapsulated in accordance with our invention broadly include all electronic components (i.e. devices, parts, etc.) for which encapsulation is desired. The term electronic component is intended to be broadly construed and includes, by way of non-limiting example, the following:

capacitors

resistors

resistor networks

integrated circuits

transistors

diodes

triodes

thyristors

coils

varistors

connectors

condensers

transducers

crystal oscillators

fuses

rectifiers

power supplies

microswitches

The definition of each of the above-identified electronic components is similarly intended to be broad and comprehensive. The term integrated circuit, for example, is intended to include, but is not limited to

large scale integrated circuits,

TTL (transistor transistor logic),

hybrid integrated circuits,

linear amplifiers,

operational amplifiers,

instrumentation amplifiers,

isolation amplifiers,

multipliers and dividers,

log/antilog amplifiers,

RMS-to-DC converters,

voltage references,

transducers,

conditioners,

instrumentation,

digital-to-analog converters,

analog-to-digital converters,

voltage/frequency converters,

synchro-digital converters,

sample/track-hold amplifiers,

CMOS switches and multiplexers,

data-acquisition subsystems,

power supplies,

memory integrated circuits,

microprocessors,

and so on.

Although our invention is not limited thereto, the composition can also contain other ingredients such as reinforcing agents and fillers.

The reinforcing agent can be, for example, glass. Fiber glass is preferred because in this form (i.e. high ratio of length to diameter) the reinforcement utility of the glass is optimized. Other forms of glass such as, for example, powder, grain and beads are, none-the-less, within the scope of our invention. Examples of other suitable reinforcing agents include, by way of nonlimiting example, asbestos fibers and ceramic fibers (e.g. aromatic polyamide fibers).

Fillers can be used to improve the dimensional stability, thermal conductivity and mechanical strength of the composition. Suitable fillers include, for example, talc, silica, clay, alumina, calcium sulfate, calcium carbonate, mica and so on. The fillers can be in the form of, for example, powder, grain or fiber. In selecting a filler the following factors should be considered:

(1) the electrical conductivity of the filler (the lower the better);

(2) tendency of the filler to decompose at encapsulation temperatures; and

(3) the level of ionic impurities in the filler.

Besides reinforcing agents and fillers the compositions of our invention can optionally contain relatively small amounts of other ingredients such as, for example, pigments and processing aids.

It should be noted that the first list of electronic components includes both active components (such as, for example, integrated circuits, transistors and diodes) and passive components (such as, for example, capacitors, resistors and resistor networks). The distinction is frequently important and is often determinative of the type of poly(arylene sulfide) encapsulation composition best suited for encapsulation of the component.

These more detailed poly(arylene sulfide) compositions, which are especially well suited for successful use as encapsulation compositions, broadly comprise the following:

(a) poly(arylene sulfide),

(b) glass,

(c) filler, and

(d) mercaptosilane.

These compositions can optionally contain, in addition to (a), (b), (c) and (d) above, relatively small amounts of other components such as, for example, pigments and processing aids.

2. Compositions for the Encapsulation of Active Components

Compositions used for the encapsulation of active components can be prepared in accordance with the following weight percentages:

    ______________________________________                                         (a) Poly(arylene sulfide)                                                      about 25 to about                                                                              45 wt % broad range                                            about 32 to about                                                                              38 wt % preferred range                                        about           35 wt % target                                                 (b) Glass                                                                      about 5 to about                                                                               30 wt % broad range                                            about 10 to about                                                                              20 wt % preferred range                                        about           15 wt % target                                                 (c) Filler                                                                     about 40 to about                                                                              60 wt % broad range                                            about 45 to about                                                                              55 wt % preferred range                                        about           49 wt % target                                                 (d) Mercaptosilane                                                             up to about     4 wt % broad range                                             about .4 to about                                                                              1.5 wt % preferred range                                       about           1 wt % target                                                  ______________________________________                                    

The above weight percentages are based upon the total amount of (a), (b), (c) and (d) in the composition.

The broad ranges represent the ranges within which the composition should be confined in order to obtain good results. The preferred ranges are preferred because they define a composition possessing the physical, chemical and electrical properties best suited for its intended encapsulation purposes. The target weight percentages represent the presently contemplated best mode.

Although our invention is not limited thereto the viscosity of the composition used for encapsulation of active components should not exceed about 800 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹). Encapsulation of active electronic components with compositions having viscosities in excess of about 800 poise can cause damage to the components. It is contemplated that the viscosity of the composition will generally range from about 150 to about 500 poise for active components other than very delicate components such as, for example, integrated circuits with wire leads. With respect to very delicate components such as, for example integrated circuits with wire leads the viscosity of the encapsulation composition should be below about 150 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹). Encapsulation of integrated circuits with compositions any higher in viscosity can cause wire wash (i.e., breaking of the wires of the integrated circuit). It is contemplated that the viscosity of the composition for the encapsulation of such integrated circuits and the like will generally range from about 75 to about 150 poise.

Although viscosity of the composition depends on a number of factors, to obtain composition viscosities below about 800 poise the viscosity of the poly(arylene sulfide) should generally not exceed about 130 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹). It is contemplated that the viscosity of the poly(arylene sulfide) will, in most applications, range up to about 70 poise. To obtain composition viscosities within the desired range for delicate active components such as, for example, integrated circuits with wire leads the viscosity of the poly(arylene sulfide) should generally be less than about 25 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹).

The purity of the composition can be measured in terms of specific conductivity of the composition. For good results the composition should be sufficiently pure such that the specific conductivity of the composition, as measured in Example V, does not exceed about 50 μs/cm. We recommend that the specific conductivity of the composition be maintained below about 20 μs/cm.

The filler is preferably silica. The silica can be amorphous silica or crystalline silica. Silica is commercially available as a finely ground material having a relatively narrow particle size distribution ranging from about 1 to about 100 micrometers. Such commercial silica is typically made up of about 99.5 weight percent SiO₂ with Al₂ O₃, Fe₂ O₃, Na₂ O and K₂ O as the remaining components.

The preferred encapsulation composition for active components is prepared from:

(a) about 32 to about 38 wt % poly(phenylene sulfide) (viscosity less than about 130 poise as tested on a capillary rheometer at 650° F. and at a shear rate of about 1000 (sec)⁻¹),

(b) about 10 to about 20 wt % fiber glass,

(c) about 45 to about 55 wt % amorphous silica, and

(d) about 0.4 to about 1.5 wt % 3-mercaptopropyltrimethoxysilane.

If the viscosity of the poly(phenylene sulfide) is below about 25 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹) this composition is especially well suited for the encapsulation of integrated circuits with wire leads. Accordingly, integrated circuits with wire leads, encapsulated with this composition, represent one embodiment of our invention.

3. Compositions for the Encapsulation of Passive Components

Compositions used for the encapsulation of passive components can be prepared in accordance with the following weight percentages:

    ______________________________________                                         (a) Poly(arylene sulfide)                                                      about 25 to about                                                                              45 wt % broad range                                            about 32 to about                                                                              38 wt % preferred range                                        about           35 wt % target                                                 (b) Glass                                                                      about 20 to about                                                                              50 wt % broad range                                            about 25 to about                                                                              45 wt % preferred range                                        about           35 wt % target                                                 (c) Filler                                                                     about 18 to about                                                                              38 wt % broad range                                            about 23 to about                                                                              33 wt % preferred range                                        about           28 wt % target                                                 (d) Mercaptosilane                                                             up to about     4 wt %                                                         about .4 to about                                                                              1.5 wt % preferred range                                       about           1 wt % target                                                  ______________________________________                                    

The above weight percentages are based upon the total amount of (a), (b), (c) and (d) in the composition.

The broad ranges represent the ranges within which the composition should be confined in order to obtain good results. The preferred ranges are preferred because they define a composition possessing the physical, chemical and electrical properties best suited for its intended encapsulation purposes. The target weight percentages represent the presently contemplated best mode.

Although our invention is not limited thereto the viscosity of the composition used for encapsulation of passive components should not exceed about 1200 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹). Encapsulation of passive electronic components with compositions having viscosities in excess of about 1200 poise can cause damage to the components. It is contemplated that the viscosity of the composition will generally range from about 500 to about 800 poise.

To obtain composition viscosities within the desired ranges the viscosity of the poly(arylene sulfide) should not exceed about 300 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹). It is contemplated that the viscosity of the poly(arylene sulfide) will generally range from about 190 to about 300 poise.

The preferred filler is talc because of its availability and ability to improve the dimensional stability, thermal conductivity and mechanical strength of the composition. In place of talc, or in combination with talc, other fillers can be used. Examples of such suitable fillers include, silica, calcium sulfate, calcium carbonate, clay and mica. Calcium sulfate is especially useful in compositions used to encapsulate connectors.

The preferred encapsulation composition for passive components is prepared from:

(a) about 32 to about 38 wt % poly(phenylene sulfide) (viscosity less than about 300 poise as tested on a capillary rheometer at 650° F. and at a shear rate of about 1000 (sec)⁻¹),

(b) about 25 to about 45 wt % fiber glass,

(c) about 23 to about 33 wt % talc, and

(d) about 0.4 to about 1.5 wt % 3-mercaptopropyltrimethoxysilane.

This composition is especially well suited for the encapsulation of capacitors. Accordingly, capacitors, encapsulated with this composition, represent an embodiment of our invention.

4. How to Make

The compositions of this invention can be made in accordance with any method wherein the poly(arylene sulfide), glass, filler and mercaptosilane are combined to form a mixture. Many suitable methods are well known to those of skill in the art. By way of example, the components of the composition can be mixed together at room temperature in a rotating drum blender or in an intensive mixer such as a Henschel mixer and then extrusion compounded at a temperature above about the melting point of the poly(arylene sulfide) to produce a uniform blend.

Once made, the composition can be used to encapsulate electronic components in accordance with any encapsulation method suitable for thermoplastic encapsulation compositions. Such methods are well known in the art. The composition can, for example, be introduced into an injection molding apparatus to produce a melt which is extruded into an injection mold wherein the electronic component to be encapsulated is positioned. Transfer molding processes are also acceptable.

The following examples are presented to facilitate disclosure of our invention and should not be interpreted to unduly limit the scope of our invention.

EXAMPLE I

The following components were intimately mixed for about 10 to 15 minutes in a tumbler type mixer:

    ______________________________________                                         poly(phenylene sulfide)                                                                          700 grams 34.6 wt %                                          .125 inch milled glass                                                                           700 grams 34.6 wt %                                          talc              600 grams 29.7 wt %                                          zinc stearate      2 grams   0.1 wt %                                          lithium carbonate  20 grams  1.0 wt %                                          ______________________________________                                    

The viscosity of the poly(phenylene sulfide) was 200 poise as tested by a capillary rheometer (Sieglaff McKelvey) at 650° F. and at a shear rate of 1000 (sec)⁻¹. The zinc stearate is an internal molding lubricant. The lithium carbonate is a mold corrosion inhibitor.

The mixture was extruded through a Davis Standard extruder at 600° F. (316° C.), ground to a granular or coarse powder and dried in an oven at 350° F. (177° C.) for 3 hours. Some of the dried material was molded into bar specimens 8 inches×1 inch×0.125 inch using a New Britain molding machine (barrel 600° F., mold 275° F.). Some of the remaining material was molded into a flat disc, 2.5 inches in diameter×0.125 inch thick, using a press mold (at 275° F. and about 6000 psi).

Three of the bars were immersed into distilled water in a pressure cooker at 120° C. and 15 psig for a total of 150 hours. The bars were then cooled, dried in an oven for a few hours at 110° C., and conditioned overnight at room temperature. Another set of 3 bars did not undergo this water boil treatment. Tensile strengths of the bars were determined in accordance with ASTM D 882-56T. The average tensile strength of the bars subjected to the water boil treatment was 59.4 MPa. The average tensile strength of the bars not subjected to the water boil treatment was 77.2 MPa. The results indicate a percent loss value of 23.0 due to the water boil treatment.

The flat disc was used to determine the electrical insulation resistance of the composition. Three holes, each 0.25 in. in diameter and located in a triangular pattern about 1.25 in. apart, were drilled in the disc. A metal bolt (with nut and washer) was attached through each hole. A single tinned copper wire was attached to each bolt. The wired disc was conditioned for 48 hours in a 95±1% relative humidity chamber at 90° C. After the 48 hour exposure the resistance between each pair of leads at a potential of 500 volts was measured using a Gen Rad Megohmeter (type 1862-C) having the capability to measure resistance up to 2×10¹² ohm. For each pair of leads two measurements were made, i.e. a first measurement and a second measurement about 1 minute after the first. After all three pairs of leads had been measured the average value of the first measurements was calculated and the average value of the second measurements was calculated. The average electrical insulation resistance was 9.9×10⁸ ohms for the first measurements and 9.5×10⁸ ohms for the second measurements.

EXAMPLE II

The preparation and test procedures of Example I were repeated with the exception that 13.5 grams of 3-mercaptopropyltrimethoxysilane (Z6062 from Dow Corning) was premixed with the talc before tumble mixing with other components of the composition.

The average tensile strength of the bars subjected to the water boil treatment was 65.6 MPa. The average tensile strength of the bars not subjected to the water boil treatment was 81.4 MPa. The results indicate a percent loss value of 19.4 due to the water boil treatment.

The average electrical insulation resistance was greater than 2×10¹² ohm for both the first and second measurements. As noted earlier the Gen Rad Megohmeter was unable to measure resistance above 2×10¹² ohm.

The results indicate that the presence of the mercaptosilane significantly increased the electric resistance of the composition without a loss in tensile strength (in fact tensile strength was improved). Results are presented in Table I below.

                  TABLE I                                                          ______________________________________                                                           Example I Example II                                         Properties        (No Silane)                                                                              (Mercaptosilane)                                   ______________________________________                                         1. Tensile Strength (MPa)                                                      a. without water boil treatment                                                                  77.2      81.4                                               b. with water boil treatment                                                                     59.4      65.6                                               c. percent loss   23.0%     19.4%                                              2. Electrical Resistance (ohms)                                                a. average first measurement                                                                     9.9 × 10.sup.8                                                                     >2 × 10.sup.12                               b. average second measurement                                                                    9.5 × 10.sup.8                                                                     >2 × 10.sup.12                               ______________________________________                                    

EXAMPLE III

The preparation and test procedures of Examples I and II were repeated except that 600 grams of calcium carbonate was used in place of the talc and, in the second run, 16 grams of 3-mercaptopropyltrimethoxysilane (A-189 from Union Carbide) was used as the mercaptosilane.

The results, presented in Table II below, again show the significant utility of a small amount of the mercaptosilane.

                  TABLE II                                                         ______________________________________                                                                     With                                               Properties        (No Silane)                                                                              (Mercaptosilane)                                   ______________________________________                                         1. Tensile Strength (MPa)                                                      a. without water boil treatment                                                                  50.6      57.3                                               b. with water boil treatment                                                                     47.5      55.0                                               c. percent loss   6.1       4.0                                                2. Electrical Resistance (ohms)                                                a. average first measurement                                                                     7.3 × 10.sup.6                                                                     >2 × 10.sup.12                               b. average second measurement                                                                    7.0 × 10.sup.6                                                                     >2 × 10.sup.12                               ______________________________________                                    

EXAMPLE IV

The preparation and test procedures of Examples I and II were repeated with the compositions indicated below:

    ______________________________________                                         poly(phenylene sulfide)                                                                               682 grams                                               glass fibers           682 grams                                               talc                   589 grams                                               ethylene bis stearamide                                                                               20 grams                                                polyethylene           5 grams                                                 pigment                9 grams                                                 silane                 X grams                                                 ______________________________________                                          Composition A: X = 0 gram                                                      Composition B: X = 13.2 grams of a 40% methanol solution of                    N{2[3(trimethoxysilyl)propylamino]ethylp-vinylbenzylammonium chloride.         ##STR1##                                                                       (Z6032 from Dow Corning Corp.)                                                 Composition C: X = 5.3 grams of 3mercaptopropyltrimethoxysilane (A189 fro      Union Carbide)                                                                 Composition D: X = 9 grams of 3mercaptopropyltrimethoxysilane (A189 from       Union Carbide)                                                           

The ethylene bis stearamide is a flow improver. The polyethylene is an internal lubricant.

The results, presented in Table III below, demonstrate the marked superiority of the mercaptosilane over not only the control (no silane--composition A) but also the silane (composition B) preferred in the prior art. Note that the electrical insulation resistance of composition C is greater than the electrical insulation resistance of composition B by nearly a factor of 10.

                                      TABLE III                                    __________________________________________________________________________                      Composition                                                   Properties       A    B     C     D                                            __________________________________________________________________________     1. Tensile Strength (MPa)                                                      a. without water boil treatment                                                                 62.0 50.9  53.1  52.0                                         b. with water boil treatment                                                                    31.8 51.0  49.7  47.1                                         c. percent loss  48.7 0      6.4   9.4                                         2. Electrical Insulation Resistance                                            a. average first measurement                                                                    2.2 × 10.sup.7                                                                3.3 × 10.sup.10                                                                2.2 × 10.sup.11                                                                >2 × 10.sup.12                         b. average second measurement                                                                   1.9 × 10.sup.7                                                                3.2 × 10.sup.10                                                                2.3 × 10.sup.11                                                                >2 × 10.sup.12                         __________________________________________________________________________

EXAMPLE V

The compositions of this example were as follows:

    ______________________________________                                         Composition: weight percent                                                                      E        F      G                                            ______________________________________                                         poly(phenylene sulfide)                                                                          34       34     34                                           fiber glass       15       15     15                                           silica            49       48.2   48.2                                         ethylene bis stearamide                                                                           1       1      1                                            black pigment      1       1      1                                            silane Z-6032     --       .8     --                                           silane A-189      --       --     .8                                           ______________________________________                                    

The poly(phenylene sulfide) was uncured Ryton™V-1 (Phillips Petroleum Co.) having a flow rate of about 3,000 to 8,000 grams/10 min. as determined in accordance with test method ASTM D 1238, Procedure B modified to use a 5 kg wt, 600° F. and a 0.0825 inch orifice). The fiber glass was chopped 1/8 inch fiber glass.

Silane Z-6032 (Dow Corning Corp.) was a 40 wt % methyl alcohol solution of N-{2-[3-(trimethoxysilyl)propylamino]ethyl}p-vinylbenzylammonium chloride. Silane A-189 (Union Carbide) was 3-mercaptopropyltrimethoxysilane.

Each composition was prepared by charging the ingredients to a Henschel mixer where they were mixed until completely dispersed. The mixture was passed through a Buss-Condux cokneader extruder at 570°-600° F. and pelletized. The pelletized compounded product was then injection molded into 1/16 inch×2.5 inch square plaques using a 35 ton ton Arburg molding machine (650° F. stock temperature, 275° F. mold temperature). Three 0.191 inch diameter holes were drilled in the plaques in a triangular pattern with mutual spacing of 1.25 inches between centers. The plaques were tested for electrical insulation resistance as described in Example I.

Specific conductivity of the compositions was also measured. The procedure for each of the pelletized compositions was as follows. The composition was ground to a coarse powder in a Willey Mill #3383-L60 fitted with a No. 40 ASTM screen. The ground material was sieved using No. 40 and No. 60 screens. The material caught on the No. 60 screen was collected. A weighed sample (0.600±0.001 grams) was put into a 100 milliliter round-bottom glass flask equipped with a Friedrich condenser and electric heating mantle. Sixty milliliters of a 0.03 wt % aqueous solution of Triton X-100 (a non-ionic surfactant ethoxylated nonyl phenol) was poured into the flask. The mixture was refluxed for 1.5 hours, cooled and filtered through a Teflon filter paper (Millipore, 25 mm, 5.0 μm No. LSWP 02500). A control sample (aqueous Triton X-100 solution only) was similarly refluxed, cooled and filtered.

The specific conductivity of the filtrate was measured using a model 252 Impedance Meter from Electro Scientific Industries. The conductivity probe was a Balsbaugh probe having a constant of 0.01 (cm)⁻¹. Specific conductivity was calculated by subtracting the conductivity of the blank (i.e. the control sample) from the conductivity of the composition-containing sample.

The results are presented in Table IV below:

                  TABLE IV                                                         ______________________________________                                                        Compositions                                                    Tests            E        F        G                                           ______________________________________                                         1.  Electrical Insulation                                                                           6.4 × 10.sup.5                                                                    9 × 10.sup.8                                                                    4.2 × 10.sup.11                         Resistance, ohms (Average                                                      of the second                                                                  measurements)                                                              2.  Specific Conductivity                                                                           10.4     10.4   5.2                                           (μs/cm) 1.5 hrs                                                         ______________________________________                                    

Composition G, containing the mercaptosilane, had both the highest resistance and the lowest specific conductivity.

Composition G is an example of a material well suited for the encapsulation of an integrated circuit.

EXAMPLE VI

This example illustrates the effectiveness of the mercaptosilane, 3-mercaptopropyltrimethoxysilane (A-189), in enhancing electrical insulation resistance of glass filled poly(phenylene sulfide) compositions that have been exposed to high relative humidity and temperature. The test samples H and I were prepared in a manner similar to the samples of Example V. Only Sample I contained a mercaptosilane. Both samples were repeatedly tested at different time intervals for electrical insulation resistance in the manner previously described. The results are graphically represented in FIG. 1 and show the effectiveness of the mercaptosilane in maintaining good electrical insulation resistance properties after exposure to heat and high relative humidity. The data show that without the mercaptosilane present resistance was greatly reduced while with the mercaptosilane resistance was greater than 2×10¹¹ at all times. 

We claim:
 1. An electronic component encapsulated with a composition comprising:(i) about 25 to about 45 weight percent poly(arylene sulfide), (ii) 3-mercaptopropyltrimethoxysilane, (iii) about 5 to about 30 weight percent glass, and (iv) about 40 to about 60 weight percent filler;wherein said weight percentages are based upon total amount of (i), (ii), (iii), and (iv); and wherein the viscosity of said composition does not exceed about 800 poise as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹.
 2. An electronic component in accordance with claim 1 wherein component (i) of said composition is poly(phenylene sulfide).
 3. An electronic component in accordance with claim 1 wherein(i) is about 32 to about 38 weight percent poly(phenylene sulfide), (ii) said 3-mercaptopropyltrimethoxysilane is present in an amount within the range of about 0.4 to about 1.5 weight percent, (iii) is about 10 to about 20 weight percent fiber glass, and (iv) is about 45 to about 55 weight percent silica.
 4. An integrated circuit with wire leads encapsulated with a composition comprising:(i) about 32 to about 38 weight percent poly(phenylene sulfide), (ii) about 0.4 to about 1.5 weight percent 3-mercaptopropyltrimethoxysilane, (iii) about 10 to about 20 weight percent fiber glass, and (iv) about 45 to about 55 weight percent silica;wherein said weight percentages are based upon total amount of (i), (ii), (iii) and (iv); and wherein the viscosity of said composition does not exceed about 150 poise as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹.
 5. An electronic component encapsulated with a composition comprising:(i) about 25 to about 45 weight percent poly(arylene sulfide), (ii) 3-mercaptopropyltrimethoxysilane, (iii) about 20 to about 50 weight percent glass, and (iv) about 18 to about 38 weight percent filler; wherein saidweight percentages are based upon total amount of (i), (ii), (iii) and (iv); and wherein the viscosity of said composition does not exceed about 1200 poise as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec)⁻¹.
 6. An electronic component in accordance with claim 5 wherein (i) is poly(phenylene sulfide).
 7. An electronic component in accordance with claim 5 wherein:(i) is about 32 to about 38 weight percent poly(phenylene sulfide), (ii) said 3-mercaptopropyltrimethoxysilane is present in an amount within the range of about 0.4 to about 1.5 weight percent, (iii) is about 25 to about 45 weight percent fiber glass, and (iv) is about 23 to about 33 weight percent filler.
 8. An electronic component in accordance with claim 7 wherein said filler is talc and wherein said electronic component is a capacitor.
 9. An electronic component in accordance with claim 7 wherein said filler is calcium sulfate and wherein said electronic component is a connector. 